new zn700 owner [Archive] - Kawasaki Motorcycle Forums

new zn700 owner

03-07-2016, 07:29 PM
I have always worked on my own cars and now that I have a 84 zn700 I want to keep working on it.

03-07-2016, 07:31 PM
My question now is I want to do the fork seals on my bike and I am wondering if I need to take any special consideration in the air suspension. I have noticed that only one side has the air valve to add air so I am guessing that at some point it crosses over to the other side. I can't see were and I am just wondering if this is going to be a bid deal when I do the fork seals. Any other suggestions will be welcome.

03-07-2016, 09:52 PM
Yep, there is a tube that connects both sides through collars on the tubes. No big deal. I replaced my fork seals twice. It'a a pain in the butt, but nothing complicated. I put a jack stand under the frame in front of the engine. I needed an impact wrench to get that small bolt out of the bottom of the tubes. It is screwed into a cylinder inside the fork leg and it spins when you try to turn the bolt. I also used a wood broom handle pressed against that cylinder to help hold it while I removed the bolt. I also bought a plastic pipe from Home Depot for about $3 and cut off a piece of it to tap the seal into place. I think it was 1 1/4" diameter as I remember, thinner than schedule 40. I used OE seals the first time. Second time I used All Balls Racing seals and they are holding up well. I reused the dust seals.

03-08-2016, 11:31 AM
The forks on my 81 650-CSR are probably very similar to yours, except for the cross-over for the air valves. my bike doesn't have that. I applied heat to the top fork caps & bottom allen bolts. For a less messy job you can rinse the internals with solvent before disassembly. I removed the fork caps, dumped out the old oil without dumping the internals, added some solvent & inverted with the fork caps in place, then dumped that out & proceeded with the job. it's a messy job.

03-08-2016, 11:37 AM
A couple more pics. I use a homemade engine block stand to support the front end. two 2x4s sandwiched together & screwed to a 2x8x16 base. lift the front wheel off the garage floor & push the stand under the engine block with your foot.

03-09-2016, 01:02 AM
Thanks. I have been sorcing the parts and will hopefully will start on it in a few weeks.

03-09-2016, 11:07 AM
The Kawasaki dealer may have the parts. fork oil seals & dust seals. may have them as well, oem or aftermarket. If something isn't listed at Z1Ent, ask, as they don't show everything on their site. I would get made in Japan if possible. some aftermarket fork seals may not be of very good quality. I've had good luck with K&L stuff --- made in Japan.